Nanoporous oxide ceramic membranes of tubular and hollow fiber shape and method of making the same

ABSTRACT

The present invention is aimed to fabricate nanoporous anodic oxide ceramic membrane tubes with excellent pore characteristics by anodizing metal tubes located in a cylindrical symmetry with respect to a cathode which itself has a cylindrical symmetry. The membrane tubes may have protruded portions acting as supports and joints. The present invention also deals with stacks and bundles consisted of numbers of the anodic oxide ceramic tubes for filter and dialysis applications.

REFERENCE TO RELATED APPLICATIONS

This is a divisional of pending U.S. patent application Ser. No.13/226,634 filed on Sep. 7, 2011 which is a divisional of U.S. patentapplication Ser. No. 12/269,649 filed on Nov. 12, 2008 and abandonedthen, the entire contents of which are incorporated herein by reference.

FIELD OF THE INVENTION

This invention relates to membranes useful in filtration and dialysisprocesses, and more specifically, the present invention is concernedwith nanoporous oxide ceramic membranes of tubular and hollow fibershape, and methods of fabricating them.

BACKGROUND OF THE INVENTION

Nanoporous anodic oxide ceramic membranes such as aluminum oxide,titanium oxide, etc. are of interest for various applications, such asfilters, gas sensors, catalysis, hemodialysis, electro dialysis, fuelcells, templates for nanostructures, life science and biomedicalapplications, and so on. Different from other ceramic membranes, theyhave through-hole pores of uniform size, so that they can effectivelyand efficiently filter harmful particles smaller than the pore sizeswithout significant fouling, which is one of the serious problems whichoccurs when using conventional porous membranes with tortuous porechannels of wide distributions in size, and thus can be used for muchlonger than conventional ones without frequent cleaning the porechannel. Furthermore, their pore size can be controlled from several toseveral hundred nanometers, so that the selectivity in filtering of thefilter incorporating the membranes is likely very excellent.

The pore size of nanoporous anodic aluminum oxide membranes can becontrolled by selecting an electrolyte among sulfuric acid, phosphoricacid, oxalic acid, malonic acid, tartaric acid, citric acid and amixture of sulfuric and oxalic acids, and applying the voltagespecifically corresponding to the electrolyte. The pores can beself-ordered in an array of a close-packed structure by a two-stepanodization process. Or the pore can be forced to be well-ordered byusing imprints where nanoscale lattice patterns of convex features arepresent.

It has been known that as the melting point of the nanoporous anodicaluminum oxide is 1,000° C., it is estimated that they can be used up to600° C. However, after heat treatment in high temperatures for phaseconversion to crystalline forms, they can be used in high temperaturesup to 1,000° C. The transformed ones are chemically very stable so thatthey can be used even in severe alkaline and acidic circumstances. Thatmeans that they can be used in ultrafiltration, nanofiltration andreverse osmosis in severely adverse acidic and alkaline environmentalconditions at very high temperatures. Also nanoporous anodic aluminumoxide membranes are compatible with human organisms so that theirapplication in life science including hemodialysis where fouling is avery severe problem, is of much attention. Furthermore, coating oflayers being capable of adsorbing harmful gas, catalytic layers orlayers with special functionality on pore walls and the surfaces of themembranes facilitates the membranes to be used as filters and sensorswith very excellent performance. So the importance of nanoporous anodicaluminum oxide membranes in filter and sensor applications has becomeprogressively large.

Nanoporous anodic titanium oxide membranes of different pore size can bemade by using similar anodization methods with those for alumina ones,except that different electrolyte may be used. The electrolyte maycomprise HF, KF, NaF, and a mixed solution of H₂SO₄ and HF, CrO₃ and HF,(NH₄)₂SO₄ and NH₄F, and (NH₄)₂SO₄ and NaF. The wall thickness oftitanium oxide anodized is generally independent of the duration of theanodizing process.

As titanium oxide also shows excellent chemical resistance, it can beused in severe alkaline and acidic atmosphere. Its three crystallinephases, anatase, rutile and brookite, shows photo-catalytic activity sothat nanoporous titanium oxide membranes can be used as filtersdecomposing environmentally harmful gases like VOC, NO_(x), SO_(x),etc., without depositing any other catalytic materials on its surfacesand pores. Furthermore, its high melting temperature of 1870° C. allowsnanoporous titania membranes to be used in high temperatures. Thereforethey can be used in severely acidic and alkaline environmentalconditions in very high temperatures.

To date, only film-type flat anodic alumina or titania membrane platesof high quality have been fabricated. By the way, application of suchplates is restricted to just a few fields, due to their relatively smallfiltering area. Most filter application requires the membranes of tubeform which are of a larger filtering area and thus offer high filteringefficiency. Even hollow fiber membranes have been used for much higherefficiency, and they have been used even in hemodialysis which needs ashort filtration time as possible. Such hollow fiber membranes, however,have been made only by using polymer-based materials. Up to now porousceramic membrane tubes have been fabricated using conventional methodslike sol-gel process based slip-casting. However, their porecharacteristic is not good as in anodic oxide ceramic membranes.Accordingly, the advent of nanoporous anodic oxide ceramic membranes oftubular and hollow fiber shapes with excellent pore characteristic willremove all the disadvantages resulting from the flat and plate shape,and accelerate their practical applications to many fields. However,there have been no reports of making nanoporous anodic oxide ceramicmembrane tubes with excellent pore characteristic.

High quality anodic oxide ceramic membranes with excellent porecharacteristic are ones where close-packed through-hole pores of uniformsize are well-arranged in an ordered manner and the porosity is high.For the fabrication of such high quality ones, by the way, special caremust be paid for uniform electric field distribution between anode andcathode, excellent heat release capability from anode duringanodization, uniform flow pattern of electrolyte, especially near thesurface of metal to be anodized, and so on. Achievement of suchrequirements is relatively easy when plates are anodized, but not easywhen metal tubes are anodized. So high quality anodic ceramic plateshave been successfully fabricated by anodizing high purity aluminum ortitanium plates using an anodization apparatus of relatively simpleconfiguration, which satisfies the requirements mentioned above.However, it is likely that satisfaction of such requirements for tubesis not simple and easy. So few try has been made to fabricate anodicoxide ceramic membrane tubes.

The present invention shows that such requirements can be fulfilled in arelatively simple manner with fabrication methods incorporatingcylindrical symmetry in arrangement of anode and cathode whichthemselves have a form of cylindrical symmetry, as well as somesupplements according to such configuration.

SUMMARY OF THE INVENTION

The present article presents methods to fabricate nanoporous anodicoxide ceramic membrane tubes and hollow fibers with excellent porecharacteristic, which were not available up to now.

The present invention provides nanoporous anodic aluminum oxide andtitanium oxide membranes of tubular and hollow fiber shape, which are ofvery high efficiency by virtue of overcoming disadvantages resultingfrom the flat shape of nanoporous anodic oxide membrane plates, and hasan object to provide fabrication methods of the nanoporous oxide ceramicmembranes of tubular and hollow fiber shape.

BRIEF DESCRIPTION OF THE DRAWINGS

The above and other objects, features and advantages of the presentinvention will be more clearly understood from the following detaileddescription taken in conjunction with the accompanying drawings, inwhich:

FIG. 1 shows a schematic set-up for fabricating tubular nanoporous oxideceramic membranes, in which the outer surface of aluminum or titaniummetal tube is anodized and the nanopores are grown inward;

FIG. 2 shows schematic drawing of a tubular nanoporous anodic alumina ortitania membrane fabricated by using the fabrication set-up shown inFIG. 1, in which the inset is exaggerated for emphasizing the differencein pore diameter between the inner and outer walls, which can appear insuch tubular membranes;

FIG. 3 shows another schematic set up for fabricating tubular alumina ortitania membranes, in which the inner surface of the aluminum ortitanium tube is anodized and the nanopores are grown outward from theinner wall;

FIG. 4 shows an aluminum or titanium tube with four protrudedrectangular bars along the z-direction on the outer wall of the tube infour-fold symmetry, in which A denotes the protruded rectangular bardesigned for a support and a joint, and B a thin layer region to beanodized;

FIG. 5 shows an aluminum or titanium tube with four protrudedrectangular bars along the z-direction on the inner wall of the tube infour-fold symmetry, in which A denotes the protruded rectangular bardesigned for a support and a joint, and B a thin layer region to beanodized.

FIG. 6 shows an aluminum or titanium tube with four protrudedrectangular bars along the z-direction in four-fold symmetry and anotherprotruded rectangular bar along the circumferential direction on thecenter of the outer wall of the tube, in which A and C denote aprotruded bar region designed for a support and a joint, and B a thinlayer region to be anodized;

FIG. 7 shows an aluminum or titanium tube with four protrudedrectangular bars along the z-direction in four-fold symmetry and anotherthree protruded rectangular bars along the circumferential direction onthe center and both the ends of the outer wall of the tube, in which Aand C denote a protruded bar region designed for a support and a joint,and B a thin layer region to be anodized;

FIG. 8 shows a cylindrical stack of three tubes of nanoporous anodicoxide ceramic membranes with different diameters, which have fourprotruded bars lying along z-axis direction in four-fold symmetry withrespect to a concentric axis, in which both upper and lower ends of allthe cylinders except for the upper end of the cylinder with the smallestdiameter are sealed; and

FIG. 9 shows a bundle consisting of seven hollow cylinders of nanoporousanodic oxide ceramic membranes, in which the lower ends of all thecylinder membranes are sealed while the upper ends are open.

DETAILED DESCRIPTION OF THE INVENTION

A simple way of making tubular porous oxide ceramic membranes isanodizing their corresponding metal tubes which are fabricated in ametal tube shape in advance. The metal tubes can be made by machiningtheir ingots and then mechanically working them to be like the drawings.The dimensions can be changed greatly depending on the size of thefilter. The diameter can be large as several ten meters and also smallas several ten microns. The tubes with diameters less than a hundredmicrons can be called hollow fibers. As the hollow fiber is one of thetubes with very small diameter, it will be included in tubes hereafter.However, very thick membranes are not desirable, because making themrequires very long anodization time, and this is especially so in thecase of mild anodization of aluminum in which the anodization occursvery slowly.

In the case of anodic alumina membranes, a thickness less than 500 μmwill be desirable. Thicknesses of 200˜300 μm may be optimal in point ofmechanical strength view for through-hole pore membranes for which 2hours will be sufficient for generating the thickness in the case of anew generation of hard anodization. However, thicknesses less than 20 μmshould be avoided due to their poor mechanical properties. It has beenknown that handling membranes thinner than 20 μm needs specialattention.

The present invention suggests two ways of anodizing the metal tubes byusing a cylindrical symmetry in arrangement of anode and cathode whichthemselves are form of cylindrical symmetry, depending on the surfaceanodized. One is that of anodizing the outer wall surface of the metaltube or hollow fiber. The oxide membrane and thus pore channel will growinward from the outer wall surface until the inner wall surface isfinally anodized. Another is that of anodizing its inner wall surface.In the latter, the oxide membrane and thus the pore channel will growoutward from the inner wall surface until the outer wall surface isfinally anodized. In principle, the present invention is for uniformlyanodizing metal tubes, and thus sets a cylindrical symmetry betweenanode and cathode, which themselves have a form of cylindrical symmetry.So it is expected that such configuration of anode and cathode resultsin uniform electric field distribution between them, and thus uniformdistribution of closed-packed pore arrangement. Also by letting a wallsurface of the metal tube be in an excellent thermal contact with heatsink and thus letting pores grow in a direction, in the presentinvention, formation of discontinuity in pore channels is avoided, whichappeared in the case of through-thickness anodization where both wallsurfaces of the metal tube are anodized.

FIG. 1 shows a schematic set-up of an apparatus for anodizing the outerwall surface of metal tube. In this set-up, metal tube which is an anodeis located in the center of an electrochemical cell for anodization. Tomaintain a uniform electrical field between the anode and the cathode,the cathode of cylindrical mesh or other similar shapes with acylindrical symmetry is located in a cylindrical symmetry outside themetal tube to be anodized. The inner wall surface of metal tube shouldbe in close contact with a heat sink in order to absorb heat generatedduring anodization and to make the anodization process proceed in asteady state. Only the outer wall surface of the metal tube is incontact with the electrolyte, and is anodized. In some cases in whichvolume expansion due to anodization may hinder ultimately close contactbetween inner wall of metal tube and heat sink, electrolyte may act as aconducting path of heat to heat sink. Also the inner wall surface shouldbe in good electrical contact with the electrode so that the hollowcylinder is anodized thoroughly up to the inner wall surface. An extrametal layer will be necessary to protect surfaces of the electrode andthe heat sink from over-anodization over the inner wall surface of metaltube. The electrolyte is stirred for uniform concentration. Thenanopores are grown inward.

The processing parameters for anodization such as applied voltage, kindof electrolyte and anodization temperature will be changed, basicallydepending on the type of anodization and the desired interpore distanceand degree of pore (i.e., cell) arrangement. Of course, the interporedistance will be dependent primarily on applied voltage, and secondarilyon current and temperature.

The membrane thickness anodized depends on anodizing time. The membranecan be made by anodizing the metal tube to a certain depth inward, andthen by removing the remaining aluminum matrix by using acidic solutionslike a mixed solution of CuCl₂ and HCl, or detaching it from theremaining metal matrix by applying a few times a voltage pulse. Or itcan be made by anodizing the tube thoroughly up to the inner wallsurface. The resulting pores will be through-hole pores. The thicknesscan be controlled by controlling the anodizing time for the formermethod, and by controlling the thickness of the tube for the lattermethod. The diameter of the tube can be changed from several ten metersto several ten microns, so that even hollow fiber membranes can befabricated by using this set-up.

In a certain condition of fabrication parameters, by the way, it isexpected that the interpore distance, i.e. the cell size, between innerand outer surfaces be slightly different, due to the difference in areabetween the inner and outer wall surfaces, where the cells areclose-packed. The interpore distance and the metal oxide cell size inthe outer wall surface are expected to be slightly larger than those inthe inner wall surface, due to larger area of outer surface, as shown inthe insert of FIG. 2. The membranes with uniform through-hole pores,whose diameter can be controlled from several to several hundrednanometers, can be fabricated by selecting the corresponding electrolyteand applied voltage, and additionally treating them in acidic solutionlike H₃PO₄ solution for pore widening.

FIG. 3 shows another schematic set-up for fabricating nanoporous anodicoxide ceramic membrane tubes by anodizing the inner wall surface. Inthis set-up, the electrolyte is contained inside the metal tube. Tomaintain uniform electrical field between anode and cathode, the cathodewhich has a shape of cylindrical symmetry like a hollow cylinder mesh ora wire string is located at the center inside the metal tube to beanodized. As the electrolyte container in this figure has a circularsymmetry, it is expected that stirring under this configuration resultsin more uniform concentration than the set-up shown in FIG. 1 does. Theouter wall surface of the metal tube should be in thermal contact with aheat sink in order to absorb heat generated during anodization and tomake the anodization process proceed in a steady state. The set-up ofFIG. 3 is expected to be more thermodynamically stable than that of FIG.1, because that of FIG. 3 offers a wider thermal contact area than doesthat of FIG. 1. It is worthwhile to notice, however, that electrolytecontained in this set-up may be limited to very small quantity in thecase of tubes with very small diameter. In some cases in which volumeexpansion due to anodization may hinder ultimately close contact betweeninner wall of the tube and heat sink, electrolyte may act as aconducting path of heat to heat sink. When the diameter of the tube isextremely small, the quantity of electrolyte contained inside the tubeis also extremely small and the heat conduction through the electrolytemay not be sufficient for cooling the tube for the steady-stateanodization. In this case, rapid circulation of electrolyte withregulated concentration and temperature is needed.

The anodization starts from the inner wall surface of tube, and thuspores are grown outward. In this set-up, the outer wall surface shouldbe in contact with the electrode so that the tube is anodized thoroughlyup to the outer wall surface. In the oxide ceramic membranes obtained byanodizing using the set-up shown in FIG. 3, the interpore distance andthe metal oxide cell size in the outer wall surface is also expectedslightly larger than those in the inner wall surface, due to a largerarea of the outer surface, as shown in the insert of FIG. 2.

By the way, as the mechanical properties of anodic oxide ceramicmembranes are very poor, the membrane tubes need mechanical support.Also as mechanical stress due to lattice expansion resulting from thetransformation of metal to metal oxide may be high, the size of theanodic oxide ceramic membranes tube may be restricted. In order to makemechanically strong ceramic membrane tubes, therefore, it is necessaryto selectively anodize some portions of the metal tube, but not all ofthem, patterned in some manner by some means. Then the rest of theun-anodized metal may be used as supports strengthening its mechanicalproperties and/or joints connecting it to neighboring structures.

A tremendously large numbers of applications exist for tubularnanoporous oxide ceramic membranes. The pore size of the membranes makesthem suited to ultrafiltration and nanofiltration applications. Theirhighly uniform pore diameter allows for excellent selectivity infiltering, and their through-hole pores are free from severe fouling andthere is a very low pressure drop therethrough. So they can be used witha very high efficiency and a long life cycle, even in applications suchas hemodialysis in which fouling is severe when conventional polymerfilters with tortuous nanopores are used. Because they are chemicallyinert to many reagents and also are stable at high temperature like 900°C., they can be chemically cleaned or burned for cleaning the pores whenthey become fouled. For example, they are inert to strongly acidic andalkaline solutions which cannot be used to clean fouled polymericmembranes. Their thermal stability makes them suitable for a variety ofhigh temperature filtration applications, the need for which cannot beaddressed by polymer membranes.

The following are examples of fabricating nanoporous anodic oxideceramic membranes of tubular and hollow fiber shape by using thefabrication set-up shown in FIGS. 1 and 3, and of assembly consisted ofnumbers of such membrane tubes for applications:

Example 1

An aluminum ingot with a purity of 99.9% or a lower grade like 95.0%were prepared and machined to a hollow cylinder with a 100 mm innerdiameter, a 120 mm outer diameter and 500 mm in length. The hollowcylinder was drawn to a tube of 10 mm inner diameter, 11 mm outerdiameter and 5000 mm long, cut into 100 mm long pieces andelectropolished to a fine surface. Some parts at both ends of the tubepiece which would be used as a support were covered with a coat toprevent the portion from being anodized.

Then the tube was anodized using a two-step anodization process asfollows: The tube was immersed in a sulfuric acid (H₂SO₄) solution at 1°C. of the anodization apparatus shown in FIG. 1 or 3, and anodized at 40V for 15 hr. For the process, an electrolyte such as phosphoric acid,oxalic acid, malonic acid, tartaric acid, citric acid, a mixture ofsulfuric and oxalic acids and a mixture of organic acids could be usedwith its corresponding voltage to generate self-ordering of porechannels, depending on the desired interpore distance. The anodizedlayer was etched out by immersing the tube in phosphoric acid for 5 hr,to prepare a seed for the second anodization. Sometimes the seed wasprepared by pressing an imprint which has a well-ordered nanoscaleconvex pattern onto the surface of aluminum tube, without performing theanodization.

Then the etched or imprinted tube was anodized at the same voltage for afew hours to several days until the surface in the opposite wall wasfinally anodized and thus through-hole pores were formed through thewall.

In the case where the aluminum tube was not fully anodized, i.e., in thecase that some thickness of aluminum was left un-anodized, the unreactedpart was eliminated by immersing the anodized body in a mixed solutionof CuCl₂ and HCl for several ten minutes, or by applying a voltagehigher by 20 V than the final anodization voltage. The oxide barrierlayer which appeared after removal of the unreacted aluminum layer waseliminated by immersing the anodized tube in a phosphoric acid solutionfor 30 min.

Then the coat at both ends of the tube was mechanically or chemicallyremoved. The nanoporous anodic aluminum oxide membrane as-preparedcontained a well-ordered array of through-hole pores 50 nm in diameter.The membranes themselves were used as catalysts and essential parts forfilters for purification of water, beverages and food, and hemodialysisand electrodialysis. Sometimes the surfaces and the pores of themembranes were coated with TiO₂, V₂O₃, WO, SnO₂, ZnO or any otherceramic oxide or polymeric adsorbent and/or catalytic materials by usingsputtering, evaporation, electrodeposition or sol-gel methods. Thecoated membrane was used for gas purification filters and photocatalytic filters to remove fine dust and environmentally harmful gasspecies such as VOC, NO_(x), SO_(x), dioxins, CO₂, CO, microbiologicalsubstances and so on.

Example 2

Aluminum ingot with a purity of 99.9% were prepared and machined to ahollow cylinder of 100 mm inner diameter, 300 mm outer diameter and alength of 500 mm. The hollow cylinder was drawn to a hollow fiber of 50μm inner diameter, 110 μm outer diameter and 5000 mm in length, cut into100 mm long pieces, and electropolished to a fine surface. Then thehollow fibers were anodized in a way similar to that described inexample 1. The nanoporous anodic aluminum oxide hollow fiber as-preparedcontained a well-ordered array of through-hole pores 50 nm in diameteron its wall. The hollow fiber membranes themselves were used ascatalysts. Also they were used for the fabrication of filters consistingof a bundle of hollow fiber membranes for purification of water,beverages and food, and for hemodialysis and electrodialysis. Sometimesthe pores of the membrane were coated with TiO₂, V₂O₃, WO, SnO₂ or ZnOby using evaporation, electrodeposition or sol-gel methods. The coatedmembrane was used for water and gas purification filters and photocatalytic filters with very high efficiency.

Example 3

Aluminum alloy ingots containing a small amount of Cu, Mn, Si, Mg, Cr,Zn, Zr, Ti, Li, Mg—Si or Mg—Si—Cr were prepared. The small amount ofmetal element was added for enhancement of the mechanical properties ofaluminum. The alloy ingots were used for fabricating aluminum tubes andhollow fibers by using the procedure described in examples 1 and 2. Thealuminum tubes and hollow fibers were electropolished and then anodizedto nanoporous alumina membranes by using the method similar to thatdescribed in example 1.

Example 4

Aluminum alloy ingots containing a small amount of one of the single,binary or ternary alloying elements listed in example 3 were prepared.The ingots were machined to hollow cylinders of 100 mm inner diameter,120 mm outer diameter and a length of 500 mm. Here the thickness of thetubes varied with circumferential position. Then the tubes were drawn totubes in which the thickness varies periodically with circumferentialposition, so that the thicker portions may be arranged with certainsymmetry around the circle. An example of such tubes with periodicallydifferent thicknesses arranged around the circle is shown in FIG. 4. Theexample has four protruded portions in a four-fold symmetry. Also tubeswith higher-fold symmetry could be prepared. The protruded thick partsin the figure were designed for use as a support and a joint forconnecting to neighboring structures if they were covered with masksduring anodization and thus were not anodized. Of course, the protrudedparts could be located in the inner wall, as shown in FIG. 5, or in boththe inner and the outer walls. Also protruded parts with other shapescould be made as shown in FIGS. 6 and 7 by using welding, lamination orriveting methods, for strengthening the membrane in other directions.While the protruded parts denoted by “A” in FIGS. 4 to 7 are supportsstrengthening the membrane in a z-axis direction, those denoted by “c,”lying along a circumferential direction in FIGS. 6 and 7 supportstrengthening the membrane along a circumferential direction. Alsoaluminum alloy tubes with protruded parts of square or rectangularshapes at both ends, which are designed for forming excellentconnections to neighboring anodic alumina membranes, could be prepared.

Then the tube with protruded parts was electropolished and then anodizedby using a procedure similar to that described in example 1, until thintube walls were thoroughly anodized and the pores in a thin wall weregrown up to the surface of the opposite wall. In order to fabricateexcellent alumina membranes of this kind of shape, special care shouldbe taken to make excellent thermal contact between the objects to beanodized and the heat sink. Sometimes the protruded parts which aredesired to be used as joints were covered with masks to prevent themfrom being anodized. Of course the pores could be grown either inward oroutward, depending on the anodization set-up used. The oxide film formedon the surfaces of thick protruded parts can play the role of protectingagainst acidic or alkaline circumstances. However, to use the protrudedparts as joints for connecting to neighboring structures by variousmethods including welding, the protruded parts could be covered by acoat before anodization to prevent the coated part from being anodized,the coat being removed after anodization.

Example 5

Hollow cylinders of 5 mm thick aluminum alloy were prepared by drawingor machining. Then the tubes of shapes shown in FIGS. 4 to 7 werefabricated using the following two methods. The first such method uses alithography technique, wherein after making a thin tube 5 mm thick, theinner or outer wall surfaces of the parts which would remain thick, suchas surfaces denoted “A” and “C” in FIGS. 4 to 7, were coated withphotoresist. Then the whole surface was exposed to ultraviolet light andthen etched until the aimed thickness for the thin part, ca. 500 μm, wasobtained. The etched tube was electropolished and then anodized usingthe procedure similar to that described in example 1. Sometimes theetched tube was anodized after removing the photo mask, in order to makethe surfaces of protruded parts resistant against acidic and alkalineenvironments.

The second method is machining or scratching out some portions from theinner or outer walls to a certain depth to make the shapes shown inFIGS. 4 to 7.

Next, the etched, machined or scratched tube was anodized by using aprocedure similar to that of example 1 until through-hole pores formedthroughout the tube wall.

Example 6

Aluminum alloy tubes 5 mm thick were prepared by drawing or machining.The inner or outer walls of the tubes were patterned using lithography,machining or scratching methods. The pattern shape can be changeddepending on the design and purpose of the membrane. The patterned tubeswere electropolished and then anodized by using a similar method to thatdescribed in example 1. The photoresist can be removed before or afteranodization.

Example 7

Three aluminum alloy tubes 5 mm thick with different inner and outerdiameters were prepared by drawing or machining. The inner and outerdiameters of each tube were adjusted to fit for adjoining the tubes in aparallel stack with a concentric axis by welding, riveting or screwing.The tubes with different inner and outer diameters were patterned toresult in the shape of FIG. 7. The tubes were anodized using differentelectrolytes and potentials corresponding to the electrolytes used, tofabricate tubular membranes with different interpore distances, by usingmethods similar to those described in example 1. Then the anodized tubeswere treated in a phosphoric acid solution to widen the pores and thusto obtain high porosity. The resulting membranes had different porediameters but almost same porosity. The resulting tubes have larger porediameters with increasing tube diameter. The pore diameters, forexample, were 200, 50 and 10 nm in 200, 100 and 50 mm ID tubes,respectively. Then the tubes were assembled into a cylinder stack with aconcentric axis as shown in FIG. 8. The cylinder stacks were used asfilters for purification of water, beverages and food, and forhemodialysis and electrodialysis, after the surface and the porechannels were functionalized in a certain manner.

Sometimes the protruded parts of the tubes were covered by a coat toprevent the parts from being deposited. Then the surfaces of the tubularmembranes were coated with TiO₂, V₂O₃, WO, SnO₂ or ZnO by usingsputtering, evaporation, electrodeposition or sol-gel methods. Then thetubes coated with oxide adsorbents or catalysts were assembled as acylindrical stack with a common central axis. The stacks of cylindermembranes was used for gas purification filters and photo catalyticfilters to remove fine dust and environmentally harmful gas species suchas VOC, NO_(x), SO_(x), dioxins, CO₂, CO, etc.

Here the stacks of cylinder membranes could be consisted of many tubes,each or a set of which can filter a specific gas species. Therefore, thestack of cylinder membranes could be used as multi-functional filterwhich can filter several gas species.

Example 8

An aluminum alloy ingot containing small amounts of Cu, Mn, Si, Mg, Cr,Zn, Zr, Ti, Li, Mg—Si or Mg—Si—Cr was prepared and machined to a hollowcylinder. The hollow cylinder was drawn to a hollow fiber of 1 mm innerdiameter, 2 mm outer diameter and 5000 mm in length, and cut into pieces100 mm long. The hollow fibers were patterned and etched to a shapeshown in FIG. 7. The hollow fibers were electropolished and thenanodized in a way similar to that described in example 1.

Then the surfaces and the pores of some fibers were coated with TiO₂,V₂O₃, WO, SnO₂ or ZnO by using evaporation, electrodeposition, sol-gelor any other coating methods. The uncoated or coated hollow fibers wereassembled to a bundle of hollow fibers as shown in FIG. 9. The bundlewas used for purification of water, beverages, food, chemicals and gas,and hemodialysis and electrodialysis.

Example 9

Aluminum alloy tube 50 mm inner diameter, 51 mm outer diameter, 100 mmin length were electropolished to 400 μm thick and then anodized usingthe procedures of examples 1. The membranes were heat-treated at hightemperatures to be converted stable alumina crystalline phase. Thenslurry or slip containing nanoscale TiO₂ was coated, dried for 24 hr andheattreated at an elevated temperature in a special atmosphere at whichhigh fraction of (001) planes of anatase phase can result in. Theresulting TiO₂/Al₂O₃ composite membranes were used in electro filtrationand so on, in which thermally and chemically stable membranes withspecial functionality like photo catalysis or NO_(x) adsorption wererequired.

Example 10

Titanium or titanium alloy tube 50 mm inner diameter, 51 mm outerdiameter, 100 mm long were electropolished to 400 μm thick and thenanodized using the procedure similar to that of aluminum oxide asdescribed example 1, except that a different electrolyte may be used.As-prepared nanoporous anodic titania membrane tubes were used forfabrication of filters of shapes shown in FIGS. 8 and 9 for filteringNO_(x), SO_(x), VOC, etc.

Example 11

Titanium or titanium alloy tube 50 mm inner diameter, 51 mm outerdiameter, 100 mm long were electropolished to 400 μm thick and then itsinner or outer surface was coated with a thin layer of aluminum. Thealuminum coated titanium (alloy) tube was anodized using the proceduresimilar to that described in example 1, until the entire aluminum layerand some of the outer or the inner layer of titanium tube was anodized.Then the anodized one was etched until the anodized alumina layer wasremoved. As a result, the surface of titanium slightly anodized, whichcontained a pattern as seed for next anodization, was obtained. Then theremaining titanium was anodized by using the procedure similar to thatof aluminum oxide as described example 1, except that a differentelectrolyte may be used.

While the present invention has been described with reference to theparticular illustrative embodiments and examples as described above, itis not to be restricted by the embodiments and examples but only by theappended claims. It is to be appreciated that those skilled in the artcan change or modify the embodiments without departing from the scopeand spirit of the present invention.

1. A method of producing a nanoporous oxide ceramic membrane comprising:providing a metallic tube in a tubular or hollow fiber shape ofpredetermined dimension; placing a cathode inside the metallic tube incylindrical symmetry to each other; placing a heat sink in contact or inclose contact with an outer wall of the metallic tube; filling anelectrolyte to soak an inner wall surface of the metallic tube and thecathode with the electrolyte; and anodizing the metallic tube to producea nanoporous oxide ceramic membrane, said anodizing performed byapplying electric current between the metallic tube as an anode and thecathode while absorbing heat produced during the anodization from theouter wall of the metallic tube via the heat sink.
 2. The method ofclaim 1, wherein the metallic tube is provided by performing mechanicalwork onto the metallic tube.
 3. The method of claim 1, wherein an outerdiameter of the membrane ranges from several tens of meters to severaltens of microns and a thickness thereof ranges from 50 mm to tens ofmicrons, and wherein the membrane comprises nanopores of 1 to 300 nm insize.
 4. The method of claim 1, wherein said anodizing is performed byanodizing from the inner wall of the metallic tube in an outwarddirection, or by anodizing both the inner and outer walls simultaneouslyin outer and inward directions.
 5. The method of claim 1, wherein themetallic tube is made of aluminum or aluminum alloy and the membrane isproduced by anodizing using an electrolyte selected from the groupconsisting of phosphoric acid, oxalic acid, malonic acid, tartaric acid,citric acid, a mixed solution of sulfuric and oxalic acids, and a mixedsolution of organic acids, and applying an electrical voltage in a rangeof 10 to 250 V.
 6. The method of claim 1, wherein the membrane isproduced by using high purity grade aluminum or low purity gradealuminum, or aluminum alloy containing one to four metal elementsselected from the group consisting of Cu, Mn, Si, Mg, Cr, Zn, Zr, Ti andLi elements.
 7. The method of claim 6, wherein the membrane is coatedwith adsorbent or catalytic materials selected from the group consistingof TiO₂, V₂O₃, WO, SnO₂, and ZnO, by using a coating method selectedfrom the group consisting of sputtering, evaporation, electrodeposition,and sol-gel, and wherein the coated layers are also nanoporous.
 8. Themethod of claim 1, wherein the membrane comprises thick protruded partsacting as supports for mechanical strengthening and joints forconnecting with another neighboring structure, and thin layers withnanopores of 1 to 300 nm in size.
 9. The method of claim 8, wherein theprotruded parts are provided by performing either lithography ormechanical working selected from the group consisting of machining,drawing, scratching, welding, and riveting, or both the lithography andmechanical working.
 10. The method of claim 1, wherein said anodizing isperformed such that an entire wall of the metallic tube between theouter wall and inner wall is anodized.
 11. The method of claim 1,wherein said anodizing is performed such that a portion of the wall fromthe inner wall of the metallic tube is anodized, and wherein the methodfurther comprises: etching, after said anodizing, the inner or outerwall of the metallic tube; and, further anodizing a remainingnon-anodized portion of the wall of the metallic tube so as to anodizean entire wall of the metallic tube between the outer wall and innerwall.
 12. The method of claim 1, wherein said anodizing is performedsuch that a portion of the wall from the inner wall of the metallic tubeis anodized, and wherein the method further comprises: imprintingperformed after said anodizing, on the inner or outer wall of themetallic tube; and, further anodizing a remaining non-anodized portionof the wall of the metallic tube so as to anodize an entire wall of themetallic tube between the outer wall and inner wall.